Offset Gear Vehicle Drive Layout for Compact Power Module Packaging
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Solution Overview
Problem
Existing vehicle drive devices face challenges in miniaturization due to the separation of housing chambers, which restricts flexibility in the arrangement and configuration of power drive units and voltage converters, leading to performance issues and increased costs.
Innovation Solution
A vehicle drive device design that includes a rotary electric machine, an output member, a power transmission mechanism, an inverter module, and a power source module housed within a case with a first housing chamber for the rotary electric machine and power transmission mechanism, and a second housing chamber for the inverter module and power source module. The power transmission mechanism incorporates an offset gear mechanism, and the inverter module and power source module are strategically arranged in the second housing chamber to optimize space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first housing chamber and the second housing chamber are separated from each other, then the power drive unit and voltage converter can be independently housed, but miniaturization of the case is restricted and flexibility for arrangement deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the second housing chamber into two distinct regions: an upper area for the power drive unit and a lateral area for the voltage converter. This spatial segmentation allows independent housing of the two components while maintaining their integration within a single case, thereby achieving miniaturization without compromising component independence or reliability.
2Reliability
If the first housing chamber and the second housing chamber are separated from each other, then the power drive unit and voltage converter can be independently housed, but flexibility for arrangement and configuration deteriorates
Solution Approach 1:
The patent utilizes dimensional arrangement by positioning the voltage converter in the lateral area of the second housing chamber, perpendicular to the upper area where the power drive unit is located. This spatial arrangement in different dimensions provides flexibility for component configuration while maintaining independent housing, allowing the case to be miniaturized without sacrificing adaptability.
3Ease of manufacture
If the power drive unit is formed according to the housing space in the first housing chamber and the voltage converter is formed according to the housing space in the second housing chamber, then components can be independently designed, but circuit performance requirements become difficult to secure or expensive components are needed
Solution Approach 1:
The patent merges the power drive unit and voltage converter into a single integrated case with a unified second housing chamber. The upper area and lateral area are both part of the same housing space, allowing the components to be independently designed and manufactured while maintaining close spatial integration. This integration enables optimized circuit performance through reduced connection lengths and improved electrical connectivity, avoiding the need for expensive components.
Data Source
AI summary
An offset gear mechanism in a power transmission mechanism is arranged on a different axis in an axis-orthogonal direction from an axis on which a rotary electric machine and an output member are arranged. The rotary electric machine and the power transmission mechanism are arranged in a first housing chamber, and an inverter module and a power source module are arranged in a second housing chamber. The second housing chamber includes an upper area on an upper side overlapping the rotary electric machine, and a lateral area on the axis-orthogonal direction first side overlapping the offset gear mechanism. At least a part of the inverter module is arranged in the upper area, and at least a part of the power source module is arranged in the lateral area.